Appendix D

Appendix D
Particle filter and backflush pump
Contents
Appendix D.1 Particle filter user manual ................................................................................
Appendix D.2 Backflush pump user manual ...........................................................................
Norwegian Greentech AS, Mjølstadnesvegen 21, 6092 Fosnavåg, Norway. Tel: +47 81 57 00 02. Email: post@norwegiangt.no
www.norwegiangt.no
Appendix D.1
Particle filter user manual
www.norwegiangt.no
Operating instructions for automatic filter
Type aquaBoll®6.18.3
Nominal diameter DN 50 - DN 500
Filter element Filter candle
Print document on both sides
NOTE:
Translation of the original operating instructions
Siemensstraße 10 - 14
50170 Kerpen
Germany
www.bollfilter.com
Date Version Language Order no. Item no.

02.2019 001 en 01
1/108
2 / 108 Operating instructions aquaBoll 6.18.3
Betriebsanleitung aquaBoll 6.18.3
Table of Contents
1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Basic safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Warning signs and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Obligations of the user/operator . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 Selection and qualifications of staff . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6.2 Maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.7 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.7.1 Filtered media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.7.2 Cleaning agent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.8 Safety instructions for operating personnel . . . . . . . . . . . . . . . . . . . 12
2.8.1 Personal safety clothing and equipment . . . . . . . . . . . . . . . . . . . . . 13
3 Transportation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.1 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 Packaging material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
5.1 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Tightening torques and lubricants for gaskets . . . . . . . . . . . . . . . . . 20
5.3 Overview of assembly groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.1 Special safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2 Filter installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.1 Floor fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.2 Installation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2.3 Identifying the flow direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2.4 Pipe connections for filter inlet and filter outlet . . . . . . . . . . . . . . . . 28
6.2.5 Flushing line pipe connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2.6 Compressed air supply connection (on pneumatically actuated
flushing valves only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2.7 Installing the gear motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2.8 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2.9 Potential equalisation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.3 Changing the flange alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
7.1 Functional description of the filter . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1.1 Filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1.2 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operating instructions aquaBoll 6.18.3 3 / 108

7.1.3 Differential pressure monitoring system. . . . . . . . . . . . . . . . . . . . . . 37
7.1.4 Gear motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.5 Flushing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.6 Control for flushing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.7 Filtration stage with filter candles . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1.8 Backflushing stage with filter candles . . . . . . . . . . . . . . . . . . . . . . . 41
7.2 Filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.2.1 Filter insert with filter candles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.2.2 Functional description of the filter insert with filter candles . . . . . . . 45
7.3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.4 Removal from service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.4.1 Short-term removal from service . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.4.2 Longer term removal from service / removal . . . . . . . . . . . . . . . . . . 48
7.4.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8 Maintenance and servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1 Contact for spare parts and service . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.2 Special safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.3 Cleaning agent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.4 Standard tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.5 Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.6 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.6.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.7 Cleaning/replacing filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.7.1 Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.7.2 Removing the filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.7.2.1 Removing the filter insert with limited removal space . . . . . . . . . . . 59
8.7.3 Removing the filter candles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.7.4 Cleaning the filter insert with filter candles. . . . . . . . . . . . . . . . . . . . 62
8.7.5 Installing the filter candles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.7.6 Installing and removing the orifice fitting . . . . . . . . . . . . . . . . . . . . . 65
8.7.7 Installing the filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.8 Inspecting the optional sacrificial anode . . . . . . . . . . . . . . . . . . . . . 68
8.9 Manually backflushing the filter in the event of power failure. . . . . . 69
8.10 Inspection and repair work on the differential pressure indicator
(optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.10.1 Arrangement and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.10.1.1 Differential pressure indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.10.1.2 Arrangement and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.10.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.10.2.1 Required tools and consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.10.2.2 Replacing the roller diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.11 Remedying faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.11.1 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.1 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.1.2 Technical data sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
9.1.3 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9.1.3.1 Spare parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

9.1.3.2 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
9.2 Supplier's documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.3 Cleaning devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.4 BOLL CLEAN 2000 cleaning agent product information . . . . . . . . 105
9.5 Worldwide sales and service network, subsidiaries and
representatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

1 Foreword
1.1 General
These operating instructions are designed to make it easier to get to know the
BOLL & KIRCH filter and make use of its proper intended uses.
The operating instructions contain all important instructions on how to operate
the filter safely, properly and economically. Adherence to the operating
instructions helps to prevent hazards, repair costs and reduce down times and
increase the reliability and even the serviceable life of the filter. Read the
operating instructions carefully and attentively.
Supplement the operating instructions with any instructions required due to
existing national and international accident prevention regulations and
environmental protection regulations. Make sure that the operating instructions
are always available in the place of use for the filter. The operating instructions
must be read and applied by every person given the task of performing the
following work:
• transportation,
• installation,
• operation,
• maintenance and servicing,
• Disposal.
1.2 Warranty and liability

The general terms and conditions of purchase of Boll & Kirch Filterbau GmbH
apply.
Boll & Kirch Filterbau GmbH shall not recognise any warranty or liability claims
for personal and material damages if they can be attributed to one or more of the
following causes:
• improper use of the filter,

• failure to comply with the information and instructions in the operating
instructions,
• Improper commissioning operation, servicing, maintenance, repair and
installation of the filter.
• arbitrary constructional modifications to the filter,
• insufficient monitoring of parts which are subject to wear and tear (e.g. filter
elements and seals),
• maintenance/repair work performed improperly or too late,
• disasters caused by external influences or an act of God.
All the information in these operating instructions is provided to the best of our
knowledge based on our prior experience. We reserve the right to make technical
changes as part of further technical development.
The text and graphic illustrations do not necessarily correspond exactly to the
actual delivery. Reference to any deviations is made in the respective place if
required for comprehension. The graphic illustrations are not true to scale.
A list of spare parts is enclosed with the operating instructions for spare parts
orders.

1.3 Copyright
These operating instructions are a certified document as per the terms of the law
against unfair competition.
The copyright of the document is held by

Boll & Kirch Filterbau GmbH
Siemensstraße 10 - 14
50170 Kerpen
Germany
These operating instructions are for the user of the filter and the user's staff. They
contain text and drawings which, without the express permission of the
manufacturer must not be
• reproduced,
• distributed or
• otherwise made available to others, either in full or in part.
Contravention will require compensation.

2 Basic safety instructions
2.1 Proper use
The filter is constructed with state-of-the-art technology and according to the
recognised rules of safety. However, use of the filter may result in risks to the life
and limb of the user or third parties and/or damage to the filter or other objects of
material value.
Only use the filter if it is in a technically perfect condition and only use it properly;
paying due attention to safety and hazards, and in adherence to the operating
instructions. It is particularly important to remedy any faults (or have them
remedied), which may compromise safety.
The filter is designed only for liquid media filtration. The filter is designed for
installation in pipes. The type of medium agreed on in the order, and the limit
values for operating pressure and temperature as defined in the technical data
must be adhered to. Any other type of use or use going beyond this use, is
regarded as improper use. The manufacturer/supplier shall not be liable for any
damage caused as a result of improper use. The user bears the sole risk.
Proper use includes observance of the operating instructions and adherence to
the inspection and maintenance conditions.
Operationally safe function is only ensured if all the instructions, settings and
performance limits for the filter, are adhered to.
2.2 Warning signs and symbols

The following designations and symbols are used in the operating instructions to
denote particularly important information:
DANGER!
Denotes immediate hazard with high risk which will cause death or serious
physical injury if not avoided.
WARNING!
Denotes possible hazard with medium risk which may cause death or serious
physical injury if not avoided.
CAUTION!
Denotes a hazard with low risk which could cause light or medium physical injury
or material damages if not avoided.
NOTE
Denotes special user tips and other particularly useful or important information.
DISPOSAL
Denotes special measures for environmental protection.
2.3 Target group

The operating instructions apply for use by qualified specialist staff only.

2.4 Obligations of the user/operator
• Always keep the operating instructions at hand at the place of use of the filter.
• Adhere to general legal and other binding accident prevention regulations
and environmental protection, and provide supplementary instructions in the
operating instructions accordingly. This type of obligation can apply to the
handling of hazardous substances or the provision/wearing of personal
safety clothing and equipment, for instance.
• Supplement the operating instructions with your own instructions, including
supervision and reporting obligations for specific operational matters, e.g.
with regard to organisation of work, working sequences and the appointed
staff.
• Only trained personnel who are familiar with the basic rules of occupational
safety and who have been instructed in handling the system may be
assigned to work on it.
• The filter may only be operated, serviced, and repaired by personnel
specifically commissioned by the user.
• Unauthorised access to the filter area is prohibited.
• Observe all existing safety instructions and hazard warnings on the filter.
• Keep all existing safety instructions and danger signs on the filter complete
(in number) and in a legible condition.
• Do not make modifications of any kind to the filter which may compromise
safety, without the permission of the manufacturer.
• The spare parts which are used must comply with the technical requirements
set out by the manufacturer. This is always guaranteed by the use of original
spare parts.
• The user is responsible for the selection of materials and the chemical
resistance of the installed components, internal linings and coatings. The
user must specify the technical details when ordering the filter.
• Note the description for any attachments and auxiliary equipment provided.
This also includes the supplier documentation and separate documentation
of external manufacturers.

2.5 Selection and qualifications of staff
• All work on the filter must be performed exclusively by reliable staff. Staff
must not be under the influence of drugs or medication. Adhere to the legal
minimum age requirement.
• Only appoint trained staff or staff who have received appropriate instruction.
Clearly delegate the areas of responsibility of staff for installation, operation
and maintenance and servicing.
The following qualifications for various activity areas are specified in these
operating instructions:
• Instructed persons were taught by the user about the work they are to
perform and possible dangers due to improper conduct and about the
required safety devices and precautions in an instruction session.
• By reason of their professional training, knowledge and experience, and
knowledge of the relevant regulations, specialist staff are able to perform the
work assigned to them and to independently recognise and avoid possible
hazards.
• By reason of their professional training, knowledge and experience, and
knowledge of the relevant standards and regulations, electricians are able to
perform work on electrical systems and to independently recognise and
avoid possible hazards. The electrician is trained for the special place of use
where they are working and knows the relevant standards and regulations.
Internal instruction must be provided taking into account the professional
qualifications of each person.
Along with the safety instructions in these operating instructions, compliance
must be ensured with the following requirements and regulations:
• the relevant accident prevention regulations
• occupational health requirements
• generally recognised rules of safety
• national regulations in the country of use
• the documentation of attachments
• the documentation enclosed with the system by the manufacturer
• the manufacturer's data (safety data sheets) for consumables, chemical
substances
• proper use
Moreover, these requirements and regulations can also be supplemented by
internal factory or company regulations.

2.6 Organisational measures
2.6.1 General
• Follow the respective valid national and international accident prevention

regulations.
• Avoid direct contact with the surfaces. Depending on the operating
temperature, there may be a risk of burns.
2.6.2 Maintenance and servicing
• Adhere to the maintenance tasks and intervals set out in the operating
instructions, including instructions on the replacement of parts/equipment.
• Only use original spare parts.
• If the filter is subject to a regular inspection by an inspection and testing
organisation, with regard to temperature, steam pressure and the
dangerousness of the medium, the inspection periods must be adhered to by
the user.
NOTE
Filter elements and seals are wear parts
During all maintenance, check the filter elements and seals for damage and
replace these.
Boll & Kirch Filterbau GmbH recommends that you keep a complete set of filter
elements and seals in stock.
2.7 Consumables
• Observe the regulations for environmental protection. Make sure that
consumables are disposed of properly and in an environmentally friendly
manner.
2.7.1 Filtered media
• When handling media which are to be filtered, make sure you follow the
respective safety regulations for the media.
2.7.2 Cleaning agent
• When handling the cleaning agents, make sure you follow the respective
safety regulations for the cleaning agents.
2.8 Safety instructions for operating personnel

Refrain from every manner of working which
– endangers the life and limb of the user or third parties,
– can damage the filter or other assets,
– impair the filter's safety and function,
– are contra to the safety instructions listed.

2.8.1 Personal safety clothing and equipment
The protective clothing and equipment required by the company must be worn
for all work on the filter. These include protective ear wear, safety shoes, safety
helmet (with face guard if required), protective clothing, protective gloves, and
face guard.

3 Transportation and storage
3.1 Transportation
DANGER!
Risk of accidents from falling loads
During transportation of the filter, accidents may occur due to sizes and weights.
• Exercise extreme caution when transporting the filter in order to prevent
damage to or deformation of the filter.
• Avoid impacts, e.g. the load falling into the slinging gear.
• Only use suitable means of transport and lifting gear with sufficient load-
bearing capacity.
• Do not stand underneath suspended loads. Do not work underneath
suspended loads.
• Wear the appropriate protective clothing.
NOTE
You can find detailed information about transport and lifting procedures in the
"Technical data" chapter of these operating instructions.
3.2 Storage
CAUTION!
Improper storage will cause damage to the filter and filter elements
If stored incorrectly and improperly, moisture and soiling, for example, may
cause damage to the filter and the filter elements.
• Protect the filter and filter elements from moisture and soiling during storage.
• Do not store the filter and filter elements below the frost line.
• If the filter and the filter elements have been stored for more than one year,
check that all seals are fully functional before installation.
3.3 Packaging material

CAUTION!
Risk of explosion from electrostatic charge
Packaging material, such as paper or plastic, can become statically charged and
generate sparks when discharged.
• Remove the packaging material before transportation into an explosive
atmosphere.
DISPOSAL
Observe the regulations for environmental protection. Make sure that the
packaging material is disposed of properly and in an environmentally friendly
manner.

4 Scope of delivery
Immediately after receiving the delivery, check that the content is not damaged
and that it corresponds to the scope of the order. In case of discrepancies,
contact the manufacturer.

5 Technical data
NOTE
You will find the technical data in the appendix of these operating instructions.
NOTE
Only fasten the transport chains or ropes to the suspension points.
• The crane hooks must be positioned above the centre of gravity for the lifting
process in order to keep the load balanced. For the centre of gravity, please
see the Technical data sheet in the appendix.
• Avoid impacts, e.g. the load falling into the slinging gear.
NOTE
The national requirements of the country of use must also be adhered to.
2x 2x
Fig. 5-1 Suspension points
5.1 Type plate

The type plate is placed on the filter. You can read the maximum permitted
operating pressure and the maximum / minimum operating temperature from the
type plate.

NOTE
When making enquiries or ordering spare parts, always indicate the information
mentioned on the type plate.
5.2 Tightening torques and

lubricants for gaskets
The tightening torques for screws and lubricants can be found on our website
Bollfilter.com under Downloads/Services or via the following link:
https://www.bollfilter.com/en/downloads/service-documents.html

5.3 Overview of assembly groups
NOTE
The description of assembly groups can be found in the "Operation" chapter of
these operating instructions.
Applies to DN 200 - DN 500
4
5
7
6
Fig. 5-2 Overview of assembly groups
1 Gear motor 6 Measuring connection

2 Type plate 7 Lower section of housing
3 Differential pressure 8 Upper section of housing
monitoring system
4 Solenoid valve 9 Cover
5 Flushing valve

Applies to DN 200 - DN 500
10
11
10 Measuring connection
11 Draining

Applies to DN 200 - DN 500 with filter candles
1
2
3
4
11
10
6
N2
9 7
8
N1 N3
Fig. 5-4 Overview of assembly groups (cross sectional view)
1 Drive shaft 8 Flushing line socket

2 Claw 9 Lower element support
3 Top flushing arm 10 Spacer pipe
4 Flushing plate 11 Upper element support
5 Connecting pipe N1 Filter inlet
6 Filter candle N2 Filter outlet
7 Bottom flushing arm N3 Flushing line

6 Installation
6.1 Special safety instructions
DANGER!
Risk of accidents from improper installation
Incorrect installation and failure to follow the listed safety instructions can lead to
accidents or damage to property.
Make sure of the following:
• The filter must be installed by qualified specialist staff or persons who have
received appropriate instruction.
• Use of the lifting gear is only permitted for authorised persons who have
• Cordon off the working and suspending area against access before lifting the
load.
• Only use suitable lifting gear with sufficient load-bearing capacity.
• Only use lifting gear on the provided suspension points (if available).
• Proceed with extreme caution when handling the loads.
• Use lifting gear in such way that the filter does not become damaged.
• Raise the filter evenly. Avoid tilting.
suspended loads.
• As there is a risk of crushing, all limbs must be kept away from separating
joints.
• Additional devices to prevent maximum temperatures being exceeded and
temperatures dropping below the minimum and for compensation and relief
of overpressure, must be provided by the user throughout the entire system
of the plant. Observe the minimum and maximum permitted operating
temperatures and pressure values for the filter.
• Additional devices for monitoring the ambient temperature of the filter must
be provided by the user throughout the entire system of the plant.
• Install a ground cable with a cross section of at least 10 mm² as a potential
equalisation for the filter.
NOTE
Contact the manufacturer with any special questions you may have regarding the
installation. The contact data for the respective national subsidiaries can be
found in the appendix of the operating instructions.

6.2 Filter installation
CAUTION!
Risk of damage to the filter housing
The filter housings are designed exclusively for internal overpressure.
• The housing and connection flanges of the filter must not be exposed to any
external force or moment.
6.2.1 Floor fastening
2
1
Fig. 6-1 Automatic filter with support leg for floor fastening
1 Lower section of housing

2 Fastening point
 Make sure the foundation has sufficient load-bearing strength.

 Make sure that there is sufficient space in the vicinity of the filter for
maintenance and servicing work.
 Align the filter.
 Screw the filter housing to the fastening points. When fastening the filter in
place, the filter housing must not be twisted.
CAUTION!
The filter has to insulated from vibrations, e.g. by using vibration dampers
between the filter and the foundation.
Likewise, the pipes on the filter inlet and outlet must be fastened in a manner in
which they are insulated from vibrations, e.g. by using vibration dampers.

6.2.2 Installation diagram
11
4
10
8
3
10
9 13
5
10
10 7
1
12
2
Fig. 6-2 Installation diagram
1 Grating/suction 8 Bypass line

strainer
2 Pump (or geodetic 9 Bypass filter (optional)
feed)
3 Filter 10 Shut-off valve
4 Controller 11 Scope of delivery (standard)
5 Flushing valve 12 Flushing valve control (valve-related)
6 to the consumer 13 Suction pump (optional)
7 Flushing line
NOTE
• Depending on the type of contamination BOLL & KIRCH Filterbau GmbH
recommends using a grating or protective pump sieve for pre-filtering.
Filter with sieve cylinder
- overall size 273 up to incl. 356: 20 mm pre-filter
- overall size 419 up to incl. 600: 35 mm pre-filter
- overall size 750: 60 mm pre-filter
filter with filter candle: 10 mm pre-filter
filter with fine sieve cylinder: 5 mm pre-filter
These values are subject to an application test by Boll & Kirch Filterbau
GmbH
• In the event of extensive soiling, the filter can be flushed out through the N4
connection.

6.2.3 Identifying the flow direction
NOTE
• The direction of flow is shown in the technical data sheet which is included in
the appendix of these operating instructions.
6.2.4 Pipe connections for filter inlet and filter outlet
 Make sure that there is sufficient space in the vicinity of the filter for
maintenance and servicing work.
 Establish the connections between the filter and piping.
 Use the appropriate seals.
 The pipes for the filter inlet and outlet may require additional supports,
depending on the installation conditions. When installing the piping, the filter
housing must not be twisted.
6.2.5 Flushing line pipe connection
 Establish the connection between the flushing line and piping.

 Use the appropriate seal.
 The pipe may need to be provided with additional supports, depending on the
installation conditions. When installing the piping, the housing must not be
twisted.
Installation
 Two bar is recommended for the pressure gradient between the filter outlet
and the flushing valve in order for the filter to achieve a good flushing effect
and not damage any components.
 The flushing line must be laid in such a way that the previous section is
fulfilled. For this, the pressure loss of the flushing line including further valves,
deflections, the overboard valve etc., must be calculated for the specified
flushing quantities.
 When installing the filter on a ship, the influence of the maximum draft
(hydrostatic back pressure) must also be taken into account.
NOTE
Please ensure that you follow the design sheet from Boll & Kirch Filterbau GmbH
when laying the pipe, which was provided to you as an attachment along with the
quote and order confirmation.
6.2.6 Compressed air supply connection (on pneumatically actuated flushing

valves only)
 Connect the plant's compressed air supply to the solenoid valve.

6.2.7 Installing the gear motor
1
2
Fig. 6-3 Gear motor installation
1 Hand winch 4 Cover

2 Screw 5 Differential pressure
monitoring system
3 Gear motor 6 Shaft
WARNING!
Risk of accidents from heavy component
During installation of the gear motor, accidents may occur due to sizes and
weights.
• Lift the gear motor using suitable lifting gear.
• Do not lift the gear motor onto the junction box.
 Clean cover and gear motor flange.

NOTE
• Install the gear motor so that the electrical connections of the gear motor and
the differential pressure monitoring system point in the same direction.
 Place the gear motor on the cover. Ensure that the feather key slides into the
groove of the shaft.
 Fasten the gear motor in place with the screws provided. Tighten the screws
evenly, gradually tightening opposite screws step-by-step.
NOTE
Pay attention to the rotation of the motor.
The drive shaft of the gear motor rotates clockwise when the motor fan turns
anticlockwise.
Fig. 6-4 Direction of rotation of the motor

 Carry out a functional test of the drive:
 Attach the hand winch to the shaft end of the gear motor.
 Rotate the hand winch three turns in the direction of the arrow (see figure
below) and release the hand winch immediately.
 Check the position of the hand winch.
It must remain in the current position.
NOTE
If you detect that the hand winch turns back automatically, there may be a
mechanical fault.
Resolve the causes of the fault and finally, repeat the functional test.
 Remove the hand winch from the gear motor.

6.2.8 Electrical connections
DANGER!
Risk of accidents from electric shock
When connecting to the power supply, the supply voltage can cause accidents
from electric shock.
• All the electrical connections on the filter must be made by a qualified
electrician and in line with the rules of electrical engineering.
Controller
NOTE
If you are using a Boll & Kirch Filterbau GmbH controller, you will find more
detailed information in the documentation for the controller.
If you are using your own controller or another manufacturer's controller, the
respective documentation must be followed.
Differential pressure monitoring system, electrical
NOTE
You will find more detailed information on the differential pressure monitoring
system in the appendix of these operating instructions or in the manufacturer's
documentation.
NOTE
Boll & Kirch Filterbau GmbH differential pressure indicators have potential-free
contacts.
CAUTION!
Risk of malfunction or damage to the filter or plant
Failure to react to the alarms can lead to malfunctions or damage to the filter or
the plant.
• Connect the differential pressure monitoring system so that the alarms are
issued.
• It is imperative to react to any active alarms and remedy the cause
immediately.
Gear motor
You will find more detailed information on the gear motor in the appendix of these
operating instructions or in the manufacturer's documentation.

6.2.9 Potential equalisation
 For potential equalisation, install a ground cable (1) with a cross section of at
least 10 mm² on the connection for the ground cable (1).
 If necessary, remove the paint from the fastening point before installing the
ground cable to ensure sufficient electrical contact.
Fig. 6-5 Ground cable connection
1 Ground cable connection

6.3 Changing the flange alignment
The design of BOLL’s aquaBoll®6.18.3 automatic filter makes it possible to
change the alignment of the outlet flange subsequently.
For this purpose, the mid housing section can be rotated in accordance with the
drilling pattern.
S3D2 standard
N3
N1 N2
Fig. 6-6 Alignment of S3D2 standard flange
1 Differential pressure indicator N2 Filter outlet

N1 Filter inlet N3 Flushing outlet
S1D2
N3
N1
N2
1
N3
Fig. 6-7 Alignment of S1D2 flange
1 Differential pressure indicator N2 Filter outlet

N1 Filter inlet N3 Flushing outlet

The alignment can cause the differential pressure indicator to fall into an
unfavourable position.
In this case, it is possible to turn the mid housing section upside down.
This in turn shifts the position of the differential pressure indicator.
In order to move the differential pressure indicator back into the correct position,
suitable fastening options are available on the console plate.
Size 273 - 356
1 1
Fig. 6-8 Fastening option for differential pressure indicator
1 Fastening option

Size 419 - 750
An optional threaded connector set is available for this purpose. Please contact
our spare parts department directly (spare-parts@bollfilter.de).
Fig. 6-9 Fastening option for differential pressure indicator
1 Fastening option
NOTE
Remove the filter insert before changing the flange alignment.
The procedure is described in the “Removing the filter insert” chapter.

7 Operation
7.1 Functional description of the filter
The filter is used for particle filtration from media in order to protect the
downstream parts of the plant. The filter is used especially for difficult
applications caused by high levels of dirty cargo, soiling which is difficult to
remove or low operating pressures.
The regeneration effect of the filter elements optimised for these applications
provides for thorough cleaning during backflushing, which in turn keeps the
pressure loss on the filter constant.
It can be used as a main flow filter or partial flow filter.
The filter elements are cleaned automatically so that the plant does not have to
be switched off for cleaning.
7.1.1 Filter housing
The filter housing contains all the pipe connections, the venting, drain hole and
the connection points for the pressure monitoring system. The lower section of
housing is screwed to the upper section of housing, which is screwed to the
cover. The gear motor is fastened to the cover.
The inside of the filter is fitted with an internal lining/coating. To protect the inner
parts, an optional sacrificial anode can be used in the filter.
7.1.2 Controller
The controller regulates and monitors all automatic filter functions.
NOTE
7.1.3 Differential pressure monitoring system
The differential pressure monitoring system measures the difference in pressure

between the filter inlet and filter outlet. As the soiling in the filter elements
increases, the differential pressure in the filter also increases.
The controller processes the electrical signals from the differential pressure
monitoring system and triggers a backflushing procedure or issues an alarm if
the differential pressure continues to rise despite backflushing having been
performed. In case of an active alarm the filter has to be taken out of service and
cleaned and/or serviced.

NOTE
• You will find more detailed information on the differential pressure monitoring
system in the appendix of these operating instructions or in the
manufacturer's documentation.
• The differential pressure can also be displayed optically on the differential
pressure monitoring system.
• The control line for the differential pressure monitoring system is fitted with
shut-off valves (e.g. ball valves).
7.1.4 Gear motor
If the pressure gradient between the dirty side and the clean side reaches a
predefined value due to the growing layer of dirt on the filter material, the filter
element cleaning function is triggered automatically.
To do so, the gear motor turns the flushing device at constant speed until the
gear motor is switched off automatically after a set time.
7.1.5 Flushing valve
The pneumatically or electrically actuated flushing valve opens and closes the
flushing line at the start and end of the backflushing stage, respectively.
NOTE
Depending on the type of actuation used for the flushing valve, the flushing valve
can be actuated manually if required, e.g. to manually backflush the filter in case
of power failure. For more detailed information, see section 8.9 of these
operating instructions.
7.1.6 Control for flushing valve
Pneumatically actuated flushing valves are controlled by a solenoid valve.

Depending on the filter design/control medium shut-off valves, one-way restrict
or valves or pressure controllers, for instance, can be connected upstream of the
solenoid valve.

7.1.7 Filtration stage with filter candles
2
N2
N1
Fig. 7-1 Filtration stage with filter candles
1 Gear motor N1 Filter inlet

2 Filter candle N2 Filter outlet
3 Flushing valve
4 Spacer pipe

In filtering mode, the medium being filtered flows into the housing via the inlet
flange.
The spacer pipe guides a partial current from the unfiltered medium into the
upper area of the housing. It flows through the two ends into the filter candles and
flows through the filter candles from the inside out. Any particles in the medium
are caught on the filter mesh of the filter candles.
The cleaned medium proceeds to the filter outlet.
The flushing valve is closed.
The gear motor is switched off.

7.1.8 Backflushing stage with filter candles
N2
4
5
8
6
N1 N3
Fig. 7-2 Backflushing stage with filter candles
1 Gear motor 7 Flushing valve

2 Top flushing arm 8 Spacer pipe
3 Flushing bush N1 Filter inlet
4 Hydrodynamic element N2 Filter outlet
5 Filter candle N3 Flushing line
6 Bottom flushing arm

The particles caught on the filter elements generate a growing differential
pressure between the filter inlet and the filter outlet.
Backflushing is triggered by the controller when the differential pressure reaches
a certain value.
NOTE
Backflushing is triggered by the controller at set time intervals in order to prevent
the backflushing device from seizing up and to prevent encrustations from
building on the filter elements, even when the maximum permitted differential
pressure has not been reached.
During the backflushing stage the filter candles are cleaned one by one by the
upper and lower flushing arms alternately.
The gear motor turns the flushing arm (which is displaced by 90°) with the
flushing plates past the individual filter candles. At the same time the flushing
valve is opened. Afterwards, this causes a high axial flow in the filter candle and
the captured particles of dirt are rinsed off.
The medium flowing lengthways through the filter candles (cross-flow
backflushing) conveys the particles of dirt out of the filter.
The hydrodynamic element which is positioned in the middle of the filter candles
increases the speed of the flow.
The dimensions of the internal parts and the additional cross-flow backflushing
generate a high backflushing effect to ensure that the filter candles are
regenerated properly. After a predefined period of time and after the flushing
arms have completed a full rotation, the control unit on the gear motor turns off.
The flushing valve is closed.
The filter is cleaned.
NOTE
• With displacement pumps the throughput is reduced by the backflushing
quantity. This backflushing quantity is only effective during the backflushing
stage.
• With centrifugal pumps or buffered systems there is no drop in throughput at
the filter outlet during the backflushing stage.
The control valve (installed by the customer) installed in the flushing line allows
the backflushing quantity to be optimised depending on the pressure and type of
contamination.
NOTE

7.2 Filter insert
NOTE
Always ensure that the filter insert is not placed on the lower bush or flushing arm
shaft outside the filter housing and that the upper and lower seal of the filter insert
are not damaged.
These seals have to be removed to perform maintenance work on a filter insert.
• When installing a filter insert, be sure to install the seals at the top and bottom
of the filter insert before installing it.
• Replace any damaged seals.

7.2.1 Filter insert with filter candles
1 2 3 4
5
10
13 12 11
Fig. 7-3 Construction of the filter insert with filter candles
1 Socket 8 Flushing device

2 Seal 9 Lower element support
3 Seal 10 Seal
4 Upper element support 11 Seal
5 Seal 12 Seal
6 Filter candle 13 Socket
7 Anchor

7.2.2 Functional description of the filter insert with filter candles
Filter inserts with filter candles are used for filtration. The flow runs from the
inside to the outside through the individual filter candles.
Particles of dirt in the flow are thus filtered off by the filter candles. The cleaned
medium exits from the side of the filter candles and is fed back into the plant.
The filter insert with filter candles comprises several filter candles arranged in
parallel. The filter candles all have the same dimensions; they are
interchangeable and can also be removed separately. The open ends of the filter
candles are situated in the upper and lower element supports. The cover plate
secures the filter candles to prevent them from sliding out upwards.
The type, version and number of filter candles used depends on the medium
being filtered.
The gap between the upper and lower element support is determined by the
length of the spacer pipe and the anchors.
The dirty side is sealed off from the clean side by seals on the upper and lower
element support or at the ends of the filter candles.
The dirt particles caught on the filter element are cleaned off using the flushing
device, which is stored in the filter element by means of the sockets.

7.3 Commissioning
CAUTION!
Risk of damage to the filter from improper filling
If the filter is filled improperly, the filter elements may be damaged.
• Filling the filter against the indicated direction of flow of the filter elements is
not permitted.
CAUTION!
Risk of contaminating the filter elements due to improper filling
During the initial commissioning of the ballast water treatment system, the filter
must be bypassed (bypass). This will prevent residue (e.g. welding beads) in the
lines from depositing on the surface of the filter elements.
NOTE
 Check whether all connections have been made properly.

 On filters with a pneumatically controlled flushing valve, open the shut-off
valves (if fitted) that are installed upstream of the solenoid valve.
 On filters with a pneumatically controlled flushing valve, check the pressure
of the control medium and adjust it as needed.
 Open the shut-off valves in the control line to the differential pressure
monitoring system.
 Open the control valve (if fitted) in the flushing line.
 Switch on the filter controller.
DANGER!
Risk of accidents from expelled medium
Hot medium (air, vapour or liquid) may be expelled during opening of the
automatic vent.
• Proceed with extreme caution.
• Keep a safe distance from the outlet opening.
DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is disposed
of properly and in an environmentally friendly manner.

 Bleed the filter as follows:
 Close the shut-off valve in the bypass line.
 Open the shut-off valve at the filter outlet.
 For displacement pumps: Completely open the shut-off valve at the filter
inlet.
 For centrifugal pumps: Open the shut-off valve at the filter inlet only
partially and after switching on the centrifugal pump gradually open the
shut-off valve at the filter inlet completely. This way you prevent pressure
surges in the plant.
 Manual venting: Open the vent directly on the cover. After venting, close
it once more.
 Automatic venting: Vent opens and closes automatically.
 After the filter has been vented completely, activate the backflushing function
manually on the control unit. The gear motor turns in accordance with the set
time and the flushing valve is activated.
 Two bar is recommended for the pressure gradient between the filter outlet
and the flushing valve in order for the filter to achieve a good flushing effect
and not damage any components.
 The filter is ready for operation.
DISPOSAL
NOTE
The filter is a pressure vessel and requires checking according to local
regulations and rules.
 If the differential pressure is preset between the filter inlet and filter outlet
during operation, backflushing is triggered automatically. The backflushing
procedure ends automatically once the set time elapses.
NOTE
Backflushing is triggered by the controller at set time intervals in order to prevent
the backflushing device from seizing up, even when the maximum permitted
differential pressure is not reached.
 If the differential pressure is not reduced by any great degree once

backflushing has been performed, either the pressure downstream of the
filter is too low or the backflushing quantity is too low as a result of excessive
throttling by the control valve in the flushing line.
 If the differential pressure increases again despite correct backflushing, an
alarm is issued. If this is the case, remove the filter from service by opening
the shut-off valve in the bypass line and closing the shut-off valves on the
filter. Remove and thoroughly clean the filter insert.

7.4 Removal from service
7.4.1 Short-term removal from service
NOTE
The flushing device has to be moved every 24 hours while the backflushing valve
is closed so as to ensure that it can be operated and restarted.
 Depressurise and drain the filter, see chapter 8, section "Preparatory work".
When using the filter in watery media, it is imperative to adhere to the following:
CAUTION!
Bachflushing of the filter after ballast water filtration
On competition of the ballast water filtration, it is recommended to carry out the
backflush cycle three times. Afterwards, it is imperative to fill the filter with fresh
water (not salt water) to prevent dirt deposits on the mesh and then hardens.
Running the filter to empty must be avoided in any event.
7.4.2 Longer term removal from service / removal
NOTE
The flushing device has to be moved every 24 hours while the backflushing valve
is closed so as to ensure that it can be operated and restarted.
 Depressurise and drain the filter, see chapter 8, section "Preparatory work".
When removing the filter and removing it from service for longer periods, pay
attention to the following points in order to prevent crevice corrosion:
NOTE
• The filter must be completely drained.
• Disconnect all connections from the filter.
• The filter must be thoroughly cleaned.
• The filter must be sealed by applying an appropriate anticorrosive, if
necessary.
• The connection flange openings must be sealed with plastic (or similar)
dummy plugs.
7.4.3 Disposal
DISPOSAL
When the filter or individual components and consumables are finally disposed
of, make sure that they are disposed of in an environmentally friendly manner.

8 Maintenance and servicing
8.1 Contact for spare parts and service
Should you require any spare parts, please contact spare-parts@bollfilter.de.
Should you require service, please contact our service team at
+49 2273/562-222 or service@bollfilter.de.

8.2 Special safety instructions
DANGER!
Risk of accidents from improper maintenance and servicing
Incorrect maintenance and servicing and failure to observe the listed safety
instructions can lead to accidents and damage to property. Make sure of the
following:
• Maintenance and servicing work must only be carried out by qualified
specialist staff or persons who have received appropriate instruction.
• When performing any work on the filter, always wear the appropriate
protective clothing.
• Use of the lifting gear is only permitted for authorised persons who have
• Cordon off the working and suspending area against access before lifting the
load.
• Only use suitable lifting gear with sufficient load-bearing capacity.
• Only use lifting gear on the provided suspension points (if available).
• Proceed with extreme caution when handling the loads.
• Use lifting gear in such a way that the filter or the components do not become
damaged.
• Raise the filter or the components evenly. Avoid tilting.
suspended loads.
• As there is a risk of crushing, all limbs must be kept away from separating
joints.
• Only perform maintenance and servicing work when the filter is cooled,
depressurised and drained. Depending on the operating temperature, there
may be a risk of burns.
• Ensure the highest levels of cleanliness when opening the filter. No foreign
substances, e.g. tools, cleaning cloths, impurities, etc., must be allowed to
remain in the filter.
• Visually inspect all seals during maintenance and replace them as
necessary.
• Clean all sealing surfaces thoroughly before assembly.
• Self-locking connecting elements (self-locking screws/nuts) should not be
reused after disassembly. Replace them with the appropriate new parts.
• On completion of the maintenance work, re-fit all available safety equipment
properly.
• Filling the filter against the indicated direction of flow of the filter elements is
not permitted.
• Remove the filter from service if the inspection periods (if indicated) have
elapsed.
• Filter elements are sensitive to pressure and impact. Always exercise
extreme caution when installing and removing the filter elements. Before
installation, check all filter elements/seals and replace any damaged filter
elements/seals.

8.3 Cleaning agent
CAUTION!
Risk of damage to the filter from incorrect use of cleaning agents
The components of the filter may become damaged if cleaning agents are used
incorrectly. The correct cleaning agent is selected in accordance with the type of
medium being filtered and the associated soiling.
• Boll & Kirch Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
agent. For more detailed information, see the appendix of these operating
instructions.
• With liquid cleaning agents, ensure that after cleaning, the filter components
are only reinstalled when completely dry.

8.4 Standard tools
The following standard tools are needed for maintenance (sample
representations of various sizes):
Open-end spanner Hex key
Circlip pliers Screwdriver
Torque wrench

8.5 Special tools
The manufacturer provides the following special tools (example illustration) for
the filter:
Key for opening the controller (if it is included

in the scope of delivery)
Hand winch for actuating the filter in case of

mains failure

8.6 Maintenance intervals
Even automatic filters have to undergo regular checks and maintenance.
It is particularly important to note that the filter material on the filter elements may
become blocked over time despite regular backflushing. This depends largely on
the quality of medium and the available partial flow cleaning function. The soiling
can be removed by cleaning the filter elements by hand using a suitable cleaning
agent. Descale any calcified filter elements.
NOTE
Boll & Kirch Filterbau GmbH recommends BOLL CLEAN 2000 cleaning agent.
For more detailed information, see the appendix of these operating instructions.
You can tell that the filter elements are becoming increasingly blocked because
the flushing intervals become shorter and shorter.
The number of backflushing cycles performed is recorded by the controller.
CAUTION!
Risk of damage to the filter and the plant from damaged filter elements
If the flushing intervals suddenly become longer, this may indicate that the filter
elements are damaged.
• In such an event, check all filter elements for damage immediately. Replace
any damaged filter elements.

In order to make sure the filter continues to operate properly, observe the
following points for maintenance:
• Check according to maintenance schedule:
– the differential pressure,
– the leak tightness of the filter, especially all connections and seals and
– the filter for corrosion and other damage and
– the condition of all screw connections and whether they are firmly
tightened.
• Check the condition of the optional sacrificial anode at least 2x per year.
Replace the sacrificial anode when the zinc mass has worn in such a way
that the carrier frame can be seen.
• Check filters at least 1x per year or filters with an ATEX rating 2x per year for
the following:
– the condition of all seals,
– the condition of all lines,
– the condition of the filter elements,
– the condition of the bearing and the bearing bush,
– the condition of all flushing bushes and
– the condition of the potential equalisation and its fastening.
Replace any damaged components.
• Check filters with an inner lining/coating for internal corrosion and any
material abrasion caused by medium contamination each time you open the
filter element or at least 1x annually. Boll & Kirch Filterbau GmbH is to be
consulted in the event that damaged surfaces have to be repaired. The
contact data for the respective national subsidiary can be found in the
appendix of the operating instructions.
• Replace all seals when overhauling the filter.
NOTE
Detailed information regarding the recommended checks on the filter and the
recommended replacement of filter elements and seals can be found in the
“Maintenance schedule” section.
NOTE
The filter elements are subject to wear from two-way strain. It is therefore
recommendable to keep a complete set of filter elements in stock.
NOTE
The filter is a pressure vessel and requires checking according to local
regulations and rules.

8.6.1 Maintenance schedule
NOTE
The following tables described the recommended checks and replacement
intervals.
The recommended replacement intervals depend on the application.
NOTE
Defective components must be replaced immediately. Only original BOLL &
KIRCH spare parts ensure safe operation and low maintenance.
Recommended checks During initial 50 h after Every 6 Every 12

commissioni the last months or months or
ng maintenance 2200 flushes 4300 flushes
or repair
Differential pressure indicator X X X
Screw connections and lines X X X
Leak tightness of the filter X X
Corrosion and other damage X X X
Condition of the sacrificial anode X X
(optional)
Condition of bearing and bearing bush X
Condition of all flushing bushes X
Condition / secure seat / electrical X
resistance of the potential equalisation
Proper function of the venting system X X
Filter element X
Recommended replacement / Every 6 Every 12 Every 24 Every 36

months or months or months or months or
2200 flushes 4300 flushes 8600 flushes 13000
flushes
Sacrificial anode X X X
Bearing, bearing bush, sliding profile, X X
flushing plates
Sockets X X
Springs X X
Filter element X
Seals X X X
Roller diaphragm for the differential X X
pressure indicator (optional)
Solenoid valve (optional) X X
Spare parts package for the 0301189 0301190 0301191
maintenance intervals after operating 8,000 h 16,000 h 24,000 h
hours

8.7 Cleaning/replacing filter elements
8.7.1 Preparatory work
NOTE
 Take the plant out of operation or open the shut-off valves of the by-pass line.
 Switch off the controller.
DANGER!
Risk of accidents due to controller being switched on unintentionally
During maintenance accidents may be caused if the controller is switched on
unintentionally, e.g. by starting up the drives or from expelled medium.
• Secure the controller to prevent it from being switched on unintentionally, e.g.
by attaching a lock.
 On filters with a pneumatically or hydraulically controlled flushing valve close

the shut-off valves (if fitted) for the control medium. Secure the control line to
prevent it from being switched on unintentionally.
 Close the shut-off valves on the connection lines. Secure the shut-off valve
to prevent it from being switched on unintentionally.
DANGER!
Hot medium can be expelled during depressurisation.
DISPOSAL
 Depressurise the filter.
DANGER!
Hot medium may be expelled when opening the drain hole.
• Wear the appropriate safety equipment and clothing.
• Collect the expelled medium in a suitable container.
DISPOSAL

 Drain the filter.
 The filter is now drained and depressurised.
8.7.2 Removing the filter insert
 Unscrew the cover screws (1).

 Lift off the cover (2).
 Lift the filter insert (3) out at the marked points (4).
NOTE
• Remove the seals at the bottom and top of the filter element.
• Do not set down the filter on the lower socket or on the flushing arm shaft.
Fig. 8-1 Filter insert (example illustration)
1 Cover screws 4 Marking

2 Cover 5 Nut
3 Filter insert

8.7.2.1 Removing the filter insert with limited removal space
If the filter’s installation location does not allow the filter insert to be pulled out due
to its limited height (as described previously), it is possible to remove the filter
insert as follows:
 Remove the nuts (5).
 Lift off the mid filter housing section with the cover.
 Place the filter housing with the cover on a suitable surface.
 Select a surface that allows the mid filter housing section to be placed on the
flange side.
CAUTION!
Setting down the filter unit on the flushing arm shaft protruding from below can
damage the filter insert.
Fig. 8-2 Removing the filter insert with limited removal space
 Continue removing the insert as described in the “Removing the filter insert”
chapter.
 Re-assembly is performed by carrying out the steps for disassembly in
reverse order.

8.7.3 Removing the filter candles
Fig. 8-3 Remove the flushing arm
1 Screws
2 Plate
 Loosen the screws (1) on the flushing arm.

 Move the plate (2) in the direction of the arrow.

3 1
4
2
Fig. 8-4 Removing the filter candle
1 Screws 5 Plate
2 Plate 6 Seal
3 Top flushing arm 7 Filter candle
4 Screws
 Remove the upper flushing arm (3).

 Remove the screws (4) on the filter element.
 Lift off the plate (5).
 Remove all seals (6).
 Pull all filter candles (7) out vertically.
NOTE
No more than three filter candles may be stacked on top of each other.

8.7.4 Cleaning the filter insert with filter candles
CAUTION!
Under normal operating conditions it is not necessary to clean the filter insert
manually. The automatic filter cleaning function keeps the pressure loss in the
filter constant. if the pressure loss increases above the permitted value, the filter
elements need to be cleaned manually.
CAUTION!
Risk of damage to the filter insert from improper cleaning
If the filter insert is cleaned or handled improperly, the filter insert may become
damaged. Observe the following safety instructions:
• Proceed with extreme caution when performing all cleaning work.
• The soaking time in the "BOLL CLEAN 2000" cleaning agent must not
exceed 24 hours.
• The cleaning temperature, when using "BOLL CLEAN 2000" must not
exceed 60 °C.
• When cleaning using a high-pressure cleaner, the pressure must not exceed
a maximum of 60 bar. When cleaning using a high-pressure cleaner, keep a
sufficient distance (at least 20 cm) from the surface of the filter material to
prevent damage.
• Particles of dirt must not be allowed to enter the clean side of the filter
element.
NOTE
Boll & Kirch Filterbau GmbH recommends BOLL CLEAN 2000 cleaning agent.
For more detailed information, see the appendix of these operating instructions.
 Remove the filter elements.

 Place the filter elements in a container of cleaning agent.
 Remove loose particles which float on the top of the cleaning agent during
the soaking stage.
 Clean the individual filter elements using a high-pressure cleaner over the
entire length and in both directions. From the outside to the inside in the final
working process.
 Then rinse out the filter elements in fresh cleaning agent.
 Allow the filter elements to dry with one opening pointing downwards or blow
the filter elements dry with compressed air.
 Remove any soiling from the other components of the filter element before
inserting the filter insert.

8.7.5 Installing the filter candles
Fig. 8-5 Filter insert with filter candles
1 Flushing arm 6 Seal

2 Screw 7 Seal
3 Plate 8 Seal
4 Seal 9 Seal
5 Filter candle
 Check all filter elements and seals for damage. Replace any damaged filter
elements or seals.
 Insert the filter candle vertically into the housing from above.
 Make sure that all seals are properly in place.
 Place the plate (3) on top.
 Attach the screws (2).
 Lubricate the seal (7).
 Attach the flushing arm (1).

1
Fig. 8-6 Flushing arm
1 Screws
2 Plate
 Move the plate (2) in the direction of the arrow.

 Tighten the screws (1).
 Mount the upper and lower gaskets (6 + 9) on the filter insert.
 Make sure that the upper and lower seal (6 + 9) are properly seated at the
filter insert.
NOTE
Mounting the lower seal
The countersunk screws on the bottom of the filter insert must be loosened by
two rotations. Now the seal can be mounted. Re-tighten the hexagon nuts.

8.7.6 Installing and removing the orifice fitting
Fig. 8-7 Orifice fitting
1 Orifice fitting
 Remove the installed orifice fitting by pulling it out.
NOTE
• Lubricate the seals (for non-rubber version only) on the new orifice
or
• Lubricate the new bezel on the smallest outer diameter.
 Press in the new orifice fitting.

 Make sure that the seals are firmly in place (for non-rubber version only;
otherwise, no seals are installed here for the other versions).

8.7.7 Installing the filter insert
 Clean any soiling which has collected on the inside of the filter.
 Check all the seals for damage. Replace any damaged seals.
 Unfasten the nuts (5).
 Lubricate the upper and lower seals before Installation on the filter insert.
NOTE
Mounting the lower seal
The countersunk screws on the bottom of the filter insert must be loosened by
two rotations. Now the seal can be mounted. Re-tighten the hexagon nuts.
 Make sure that all seals are properly in place.

 Lift up the filter insert (3) at the marked points (4).
 Before installing the filter element, lubricate the top and bottom seals on the
filter element.
 Place the filter insert (3) into the filter.
 Check that the backflushing device moves easily.
 Attach the cover (2).
 Make sure that the seal is properly in place.
 Fasten the cover (2) with screws (1) and tighten evenly crosswise.
 Tighten the nuts (5) evenly, in a crosswise manner.
 Close the drain hole.
 Put the filter back into operation. See chapter 7, section "Commissioning".

1
Fig. 8-8 Filter insert (example illustration)
1 Cover screws 4 Marking

2 Cover 5 Nut
3 Filter insert

8.8 Inspecting the optional sacrificial anode
NOTE
The sacrificial anode (3) is fastened to the inner side of the inspection opening
cover (2).
 Remove the nuts on the inspection opening cover (2).

 Pull the inspection opening cover out of the housing along with the sacrificial
anode (3).
 Inspect the condition of the sacrificial anode (3). The sacrificial anode (3)
must be replaced when the zinc mass has worn down enough for the carrier
frame to be seen.
 Check the seal for damage. Replace any damaged seals.
 Place the inspection opening cover (2) in front of the inspection opening
along with the inspected or new sacrificial anode (3).
 Make sure that the seal is properly in place.
 Fasten the inspection opening cover (2) with nuts and tighten evenly
crosswise.
1 1
Fig. 8-9 Sacrificial anode (example illustration)
1 Earthing connection 3 Sacrificial anode

2 Inspection opening cover
CAUTION!
Without the potential equalisation (top housing to bottom housing and cover), the
anodic protection does not work.
• For BWT applications, fresh water must be filled in at every standstill.

8.9 Manually backflushing the filter in the event of power failure
WARNING!
Risk of accidents caused by the filter starting back up
When the electrical power returns, the filter may start up again and the rotating
movement of the hand winch attached to the gear motor may injure you.
• Before manually actuating the filter, first switch off the controller.
• Before switching on the controller, remove the hand winch from the shaft end
of the gear motor.
DANGER!
Risk of accidents due to controller being switched on unintentionally
When manual backflushing is being performed accidents may be caused if the
controller is switched on unintentionally, e.g. by starting up the drives.
• Secure the controller to prevent it from being switched on unintentionally, e.g.
by attaching a lock.
 Switch off the controller.

 Open the flushing valve on filters with
 a pneumatically or hydraulically actuated flushing valve by turning the
emergency actuation screw on the solenoid valve or
 an electrically actuated flushing valve - see further information on manual
actuation in the appendix to these operating instructions or in the
 Attach the hand winch to the shaft end of the gear motor.
 Carry out filter backflushing by turning the hand winch.
NOTE
Approximately 300 - 400 turns are required to completely backflush the filter
depending on the gear motor.
 As soon as the differential pressure has been reduced, remove the hand
winch from the gear motor.
 Repeat the manual backflushing process by turning the hand winch until the
normal power supply has been recovered.
 Once the normal power supply has been recovered, close the flushing valve.
For filters with:
 a pneumatically or hydraulically actuated flushing valve by turning the
emergency actuation screw on the solenoid valve back into the original
position or
 an electrically actuated flushing valve - see further information on manual
actuation in the appendix to these operating instructions or in the
 Switch on the controller.

8.10 Inspection and repair work on the differential pressure indicator
(optional)
8.10.1 Arrangement and operation
8.10.1.1 Differential pressure indicator
12 1
11
10
4
5
8 7 6
1 Cover 7 Piston
2 Housing 8 Spring
3 Connection chamber 9 Seal
4 Sealing plate 10 Display
5 Screw 11 Indicator dial
6 Roller diaphragm 12 Adhesive label (switching
pressure)

8.10.1.2 Arrangement and operation
A piston which is sealed with a roller diaphragm divides an area into two
chambers which ate connected to the filter inlet and filter outlet. The line from the
filter inlet is connected to the sealing plate.
As the soiling increases, the differential pressure between the filter inlet and filter
outlet also increases. This causes the piston to press against the spring and shift
in accordance with the extent of differential pressure.
Magnetic transmission of force turns the display dial in accordance with the
piston motion and red segments become visible in the windows of the display. If
the display windows are completely filled with red, the maximum differential
pressure value has been reached.
Types 4.36.2(.x) and 4.46.2(.x) are equipped with Reed contacts in the
connection chamber which are actuated magnetically by the piston. The
differential pressure levels at which the contacts are actuated are printed on the
adhesive label.
8.10.2 Maintenance work
8.10.2.1 Required tools and consumables
To perform the work you only require standard tools.
CAUTION!
Risk of damage to the device due to use of unsuitable grease
The grease used for lubricating the moving parts must be matched to the
medium.
8.10.2.2 Replacing the roller diaphragm
For the following description it is assumed that the differential pressure indicator
is separate; if necessary the differential pressure indicator will first have to be
detached from the other components/assembly groups.
 Unfasten the screws on the side

sealing plate.
 Remove the sealing plate.

 Remove the roller diaphragm and
check the roller diaphragm for
damage.
If the roller diaphragm is damaged,
replace it with a new part.
 Check that the optical display is fully

functional. To do so, press the
piston down with your thumb and
check whether red fields become
visible in the windows of the optical
display.
 Remove the piston and spring.

 Clean the inside and check it for
damage.
NOTE
Make sure that the spring can be clearly assigned to the device when reinstalling
and make sure there can be no mix up.
CAUTION!
The pressure display may be altered if other springs are used
Only the installed spring or an equivalent original spare part for the special type
of differential pressure indicator may be used.
If you use other springs, the pressure indicator, i.e. the switch points, will be
altered.
Only replace a damaged spring with an original spare part.
NOTE
The operating pressure range may be changed by installing the respective
spring. The scope of delivery of the spring includes an adhesive label which has
to be attached to the cover in place of the previous adhesive label.

 Turn down the roller diaphragm. To
do so, place the roller diaphragm on
a clean surface as shown and press
the middle of the diaphragm down
with your finger.
Make sure the cross-shaped raised
part of the roller diaphragm is in the
correct position (see illustration).
 Lightly grease the spring, piston and
roller diaphragm.
 Fit the roller diaphragm to the piston

and inset the spring in the piston.
 Install the parts in the differential
pressure indicator housing.
The illustration opposite shows how the

components should be if installed
correctly. The roller diaphragm
protrudes slightly from the housing.
 Place the sealing plate centrally on

the roller diaphragm and screw the
sealing plate to the housing evenly.
The differential pressure indicator is now ready for use.

8.11 Remedying faults
NOTE
In case of any faults or repairs which are not listed here, contact the BOLL &
KIRCH customer services department.
8.11.1 Trouble shooting
Fault Possible cause Remedy

Flushing performed High level of soiling in Determine the cause of
often the medium soiling in the plant
Filter elements blocked Change / clean the filter
elements
The gear motor does not Flushing arm blocked Open the filter and
turn remove the cause of the
blockage
No power supply Check the power supply
Controller is set Correct the setting or
incorrectly or is faulty replace the controller
Differential pressure will Filter elements blocked Change / clean the filter
not reduce elements
Fresh water filling not Fill with fresh water
completed during standstill
The pressure Set the pressure,
downstream of the filter increase the backflushing
is too low or the quantity
backflushing quantity is
too low
Flushing valve does not Check function / clean /
open replace
No differential pressure Shut-off valves in Open shut-off valves
indicator control line closed
Differential pressure Check/replace the
monitoring system faulty differential pressure
monitoring system
Filter with pneumatically / hydraulically actuated flushing valve
The solenoid valve does Shut-off valve in the Open shut-off valve
not activate supply line closed
Control pressure too low Check / set the pressure
Controller is set Correct the setting or
Filter with electrically actuated flushing valve
Flushing valve does not No power supply Check the power supply
switch Controller is set Correct the setting or

9 Appendix
9.1 Filter
9.1.1 Technical data
Filter
Filter type aquaBoll 6.18.3
Nominal connection diameter DN 80
Housing size 273
Fluid to be filtered ballast water
max. flow rate 50.00 m³/h
Fine filter units 25 µm
Mesh number 155
Maximal zulässiger Druck 10.00 bar
permitted max. operating temperature 60.00 °C
Operating voltage 3 ph 440 Volt
Frequency 50 Hz
Control voltage 230 Volt
Motor output 0.090 kW
Backflushing medium Internal medium
Minimum operating pressure after filter 2.00 bar
Filter element
Element type of filter Fine sieve cylinder of stainless steel
Number of filter elements 1

9.1.2 Technical data sheet

9.1.3 Spare parts
9.1.3.1 Spare parts drawing

9.1.3.2 Spare parts list
Document Description Date

354149 automatic filter 14.04.20
aquaBoll
Dimension drawing: Z154933
Assembly: Z149256,Z153484
Item ID no. Description Quantity Unit

0632524 1 pcs.
3270004 gasket 1 pcs.
9801149 type plate 1 pcs.
2380014 crank handle 1 pcs.
00004 5370099 1 pcs.
00050 2215678 disc 24 pcs.
00060 2011228 Hexagon Screw 8 pcs.
M16x110
Material: A4-70
EN ISO 3506-1
00061 2011307 Stud Bolt 8 pcs.
M16x75
Material: A4-70
EN ISO 3506-1
00062 2011064 lifting screw 4 pcs.
M8
Material: VA/Stainless Steel
00063 2010305 lifting screw 2 pcs.
M16
Material: A4-21H
EN ISO 3506-3
00070 2110019 hexagon nut 16 pcs.
M16
Material: A4-70
EN ISO 3506-2
00080 3550111 gasket 1 pcs.
00085 3090741 o-ring 2 pcs.
00100 5013343 anchor bolt 6 pcs.
00101 5360068 bushing 2 pcs.
00103 5013347 plate 1 pcs.
00104 5013346 plate 4 pcs.

00105 5013344 plate 2 pcs.
00106 5013348 plate 1 pcs.
00150 2210048 disc 6 pcs.
00160 2011170 countersunk screw 6 pcs.
M8x25
Material: A4-70
EN ISO 3506-1
00161 2010624 hexagon socket head cap screw 2 pcs.
M8x20
Material: A4-70
EN ISO 3506-1
00170 2110078 self-locking hexagon-head nut 6 pcs.
M8
Material: A4-70
EN ISO 3506-2
00180 3550155 gasket 1 pcs.
00181 3550203 gasket 1 pcs.
00182 3040414 o-ring 2 pcs.
00190 1940962 fine sieve cylinder BWT20 1 pcs.
00201 5410349 shaft 1 pcs.
00202 5310289 bushing 1 pcs.
00203 5013452 +locking plate 1 pcs.
00204 5013340 plate 1 pcs.
00207 5310290 bushing 1 pcs.
00208 5013670 plate 2 pcs.
00210 5710530 connecting pipe 1 pcs.
00213 5013667 plate 3 pcs.
00214 5013664 sheet 2 pcs.
00215 5015128 plate 1 pcs.
00217 5310389 bushing 2 pcs.
00219 5013674 plate 2 pcs.
00220 2310242 shaft spring 1 pcs.
00222 2310226 pressure spring 1 pcs.
00223 5013986 +sheet 6 pcs.
00250 2210048 disc 2 pcs.
M8x20
Material: A4-70
EN ISO 3506-1
M8x50

Material: A4-70
EN ISO 3506-1
M6x50
Material: A4-70
EN ISO 3506-1
M6x16
Material: A4-70
EN ISO 3506-1
M6
Material: A2-70
EN ISO 3506-2
M8
Material: A4-70
EN ISO 3506-2
00280 3090069 o-ring 1 pcs.
00281 3090770 o-ring 2 pcs.
00300 5410465 shaft 1 pcs.
00302 5370056 bushing 1 pcs.
00304 5310384 bushing 1 pcs.
00305 5012829 plate 1 pcs.
00306 9800911 label 1 pcs.
M10x25
Material: A4-70
EN ISO 3506-1
00361 2016174 hexagon screw 4 pcs.
M8x20
Material: A4-70
EN ISO 3506-1
00380 3090741 o-ring 2 pcs.
00381 3390057 flat gasket 1 pcs.
00390 4500552 gear motor 1 pcs.
00390 4100097 cable gland 1 pcs.
00390 3250001 cone plug 1 pcs.
00391 2206218 locking ring 1 pcs.
00400 5013311 flange 1 pcs.
00401 5011965 anchor bolt 2 pcs.

00402 5013274 retaining plate 1 pcs.
00403 6710662 plate 1 pcs.
00404 5011625 distance tube 5 pcs.
00410 5013275 sacrificial anode 4 pcs.
00450 2210131 disc 4 pcs.
M12x20
Material: A4-70
EN ISO 3506-1
00461 2010965 stud bolt 4 pcs.
M12x60
Material: A4-70
EN ISO 3506-1
M10x16
Material: A4-70
EN ISO 3506-1
00470 2110175 hexagon nut 4 pcs.
M12
Material: A4-70
EN ISO 3506-2
00480 3090787 o-ring 1 pcs.
00500 5011883 flange 1 pcs.
00500 5011883 flange 1 pcs.
00500 5011883 flange 1 pcs.
00503 5011635 flange 1 pcs.
00550 2210037 disc 12 pcs.
M10x35
Material: A4-70
EN ISO 3506-1
00561 2012537 screwed sealing plug 1 pcs.
EG1/2"
Material: A4-70
EN ISO 3506-1
EG1/2"
Material: A4-70
EN ISO 3506-1
EG1/2"

Material: A4-70
EN ISO 3506-1
00580 3090065 o-ring 4 pcs.
00581 3210014 gasket 1 pcs.
G1/4"
Material: A4-70
EN ISO 3506-1
00600 2811017 Flange 1 pcs.
00650 2210037 disc 4 pcs.
M10x40
Material: A4-70
EN ISO 3506-1
00680 3090092 o-ring 1 pcs.
00900 6710897 console 1 pcs.
00960 2314837 blind rivet 4 pcs.
M8x16
Material: A4-70
EN ISO 3506-1
00962 2010702 shear screw 1 pcs.
M8x16
Material: A2-70
EN ISO 3506-2
M6x16
Material: A4-70
EN ISO 3506-1
01050 2210016 disc 9 pcs.
01050 2210016 disc 1 pcs.
01059 2203361 toothed lock washer 5 pcs.
M8x12
Material: A4-70
EN ISO 3506-1
01061 2010344 stud bolt 1 pcs.
M8x40
Material: A4-21H
EN ISO 3506-3
01080 2110016 hexagon nut 2 pcs.

M8
Material: A4-70
EN ISO 3506-2
01090 9800551 label protective conductor S 1 pcs.
01091 4100181 grounding lug 2 pcs.

9.2 Supplier's documentation
NOTE
Documentation for any components or assembly groups purchased externally by
Boll & Kirch Filterbau GmbH is enclosed with these operating instructions.
Adhere to the information contained, in particular information on the subject of
safety.
9.3 Cleaning devices

For particularly good cleaning results, Boll & Kirch Filterbau GmbH recommends
the filter element cleaning unit type 5.04 with rotating nozzle and flat jet nozzle or
optionally, the type 5.05 ultrasonic cleaning unit.

9.4 BOLL CLEAN 2000 cleaning agent product information
Product description:
BOLL CLEAN 2000 is a liquid cleaning and degreasing agent with a broad range
of applications. It can be used practically for all cleaning and degreasing needs.
BOLL CLEAN 2000 cleans quickly and thoroughly and is extremely economical.
The use of BOLL CLEAN 2000 renders all safety precautions unnecessary.
BOLL CLEAN 2000 has all these excellent characteristics without the
disadvantages of solvent-based cleaners.
BOLL CLEAN 2000 is:
• not inflammable
• not subject to compulsory identification markings
• not strong smelling
• not corrosive
• physiologically harmless
• biodegradable
• Umweltbundesamt (Federal German Ministry of Environment) reg. no.
04860019
BOLL CLEAN 2000 can be overcooled or overheated during storage but is then
fully useable when at normal temperature again.
Sieve mesh contaminated with heavy oil:
Sieve meshes which are contaminated with heavy oil must be soaked in normal,
commercially available solvent. After soaking, the sieves are cleaned in the
BOLL & KIRCH cleaning device type 5.04 with BOLL CLEAN 2000 and high-
pressure pump.
Instructions for use:
BOLL CLEAN 2000 is not processed for any specific cleaning method. BOLL
CLEAN 2000 can be used in a soaking bath, in a spray unit, in a steam jet cleaner
or be applied by hand, using a cloth, brush or sponge, depending on the
operational conditions.
It can be used cold or warm.
BOLL CLEAN 2000 can be mixed with water - even with sea water.
• Concentration for mesh cleaning: 1 : 2,5
• Maximum temperature up to 60 °C
The concentration depends on the type and extent of the collected dirt particles
which have to be removed. When using a concentration of 1 : 30 and above,
rinsing is usually not necessary. No visible film is left on the surface.

9.5 Worldwide sales and service network, subsidiaries and
representatives
If you require service or spare parts, please contact the main site or our
subsidiaries, representatives or service points.

Appendix D.2
Backflush pump user manual
www.norwegiangt.no
Installation, Operation and Maintenance instructions
AE_, AKN_, AL_, AP, AT, K_,

L_, T
Inline centrifugal pumps
4.11.2019/Kolmeks käyttöohje EN rev 2.docx

1 GENERAL
This product has safe and reliable operation in the function for which it is specified. A pump is a piece of equipment that has
pressurized parts and rotating parts which can be dangerous. Thus, fully follow all the safety measures in the instructions.
Personal injuries are possible if you do not follow the instructions.
The main heading Safety Instructions includes general health and safety instructions and also other safety information related to
this supply. Such information includes all important requirements of national legislation and other safety information given by the
plant operator.
The correct process and application data is important for the safe and reliable operation of the product. Environmental
circumstances must be specified to Kolmeks before the pump delivery.
Such conditions are for example:

- Unusual temperature
- High humidity
- Atmospheres that cause corrosion
- Pressure changes in the process
- Flow below the minimum permitted, dry running
- Explosive and/or fire hazard areas
- Dust, sandstorms
- Earthquakes
Special safety measures are also necessary when the liquid that goes through the pump is for example:
- Flammable
- Corrosive, abrasive
- Poisonous
- Crystallizing
- Solids-containing
- Gas-containing
You must follow the safety and operation instructions. If these are not followed, a risk to the personnel and the environment is
possible, for example:
- Failure of important functions of the pump and/or plant
- Failure of specified procedures of maintenance and repair
- Risk of electrical, mechanical and chemical hazards to the personnel
- Environmental risk because dangerous material is released
2. SAFETY OF MACHINERY
2.1 General
The supply does not include the design of the operation environment of the machine, the power circuits, control
circuits and controls of machine operation. However, the European Machinery Directive 2006/42/EC on the safety
of machines and/or related national legislation of the country where the machine is used are mandatory related to
the necessary health and safety requirements in the operation of the process.
It is necessary that the Customer has taken into account the necessary requirements that are shown in this
instruction when designing, purchasing and starting up the process control systems, other controls and equipment
related to the machine. Some of these requirements are also applicable to the personnel that operate the machine.
As far as the above is applicable, the Customer must also follow the appropriate legislation on electrical safety
(such as the low-voltage directive 2014/35/EU) or electromagnetic compatibility of equipment (EMC directive
2014/30/EU). During the operation of the machine you must also follow the appropriate occupational safety
legislation of the country where the machine is used.

2.2 Necessary health and safety requirements
2.2.1 General remarks
2.2.1.1 Definitions
When necessary, the potential dangerous areas related to the machine and its operating environment, persons
working in the dangerous areas and all operator groups of the machine must be specified together by the Customer
and the Manufacturer. This may be necessary for example because of operation training arranged for the operators
of the machine.
2.2.1.2 Principles of safety integration
To ensure safety integration, as a machine manufacturer we follow the Machinery Directive and/or the national
legislation of the country where the machine is used as far as the supply is concerned. The installation, operation
and safety instructions supplied with the machine must be followed in the reception of the machine, in installation
and in operation. Before actual start-up, make sure that the machine, its controls and other equipment related to
the safe operation of the machine comply with the requirements given in the Machinery Directive and/or in national
safety legislation.
2.2.1.3 Materials and products
The products related to the use of the machine (such as liquids transferred in the process) must not endanger the
exposed persons' safety or health. The process where the machine is used must be designed so that the use of
liquids causes no hazard.
2.2.1.4 Lighting
Maintenance areas necessary for the regular inspections of the machine must have appropriate lighting.
2.2.1.5 Design of machinery to facilitate its handling
The environment of the machine must enable the moving of the machine or its components safely. If necessary,
the upper part of the machine can be attached to standard lifting equipment. You must fully follow the moving and
lifting instructions supplied with the machine.
2.2.2 Controls
2.2.2.1 Control and stopping devices
It must be possible to use the controls of the machine safely, and the controls must be designed in a manner that
will prevent a dangerous situation from occurring.
Follow the specified requirements related to controls, starting devices, stopping devices (including emergency stop
devices) and selection of control and operating modes for the machine and combinations of machinery. Refer to
the Machinery Directive and/or the national legislation of the country where the machine is used.
The controls of the machinery must be able to prevent fluctuations in energy supply or failures in the control circuit,
potentially causing dangerous situations. The interactive software used in the controls between the operator and
the machine must be easy to use.
2.2.3 Protection against mechanical hazards
2.2.3.1 Stability
You must follow fully the installation instructions supplied with the machine. This is to make sure that the machinery
is sufficiently stable.
2.2.3.2 Risk of damage during operation
The piping and hoses connected to the machine must be resistant to the internal and external forces. They must be
tightly attached and must withstand all loading and forces.
During operation, there is always a risk of damage to the piping connected to the machine (risk of high-
pressure/hot/harmful liquid spray) if the supplied instructions are not followed.

2.2.3.3 Risks because of falling or ejecting objects
Follow the necessary precautions to prevent objects from falling or ejecting (e.g. tools used during installation).
2.2.3.4 Risks because of sharp edges or angles
Because of the functioning and design of the machine, its parts have sharp edges and/or angles. During installation
and maintenance, follow the instructions supplied with the machine and use the applicable personal protective
equipment.
2.2.3.5 Risks related to changes in the rotational speed
The instructions supplied with the machine show the usual rotational speed of the machine and its maximum
rotational speed limits. Follow these instructions when you select the rotational speed of the pump.
2.2.3.6 Risks related to moving parts
The installed guards used to prevent risks related to moving parts in the machine must be fully in position when the
machine is in operation. If guards are not included in the supply, make sure before start-up that the rotating parts
have protection. Also refer to the applicable legislation.
If rotating parts of the machine do not move freely during operation, stop the machine immediately. Find out the
cause of the failure. Refer to the instructions supplied with the machine.
2.2.4 Protection against other hazards
The electrical drives of the machine must have a design that prevents all electrical hazards. Follow the specified
rules and applicable legislation related to electrical equipment. The electrical equipment related to a machine that
complies with the Machinery Directive must follow the requirements shown in standard EN 60204-1:2006.
2.2.4.1 Static electricity
The build-up of potentially dangerous electrostatic charges in the machine and its auxiliary equipment must be
prevented or restricted.
2.2.4.2 Errors of fitting
Errors made when you install parts of the machine can be a source of risk. Because of this, follow fully the
instructions supplied with the machine during the installation and repairs of the machine.
Incorrect liquid and electrical connections can also be a source of risk. With liquid connections, follow the
instructions supplied with the machine. Incorrect electrical connections must not be possible or information on the
risk must be marked on cables and connectors.
2.2.4.3 Very high temperatures
If necessary, the machine must have warnings related to high surface temperatures. In these conditions, the risk of
injury caused by touching of the machinery parts must be decreased. Because of maintenance it is necessary to
heat of some parts before installation. Be careful during installation, and use applicable personal protective
equipment.
2.2.4.4 Fire and explosion
Correct and accurate information on the process and the functioning of the machine are necessary for the safe
operation of the machine. The special conditions at the point of operation must always be examined between the
Customer and Manufacturer when the machine is selected.
2.2.4.5 Noise and vibration
Noise level (dB [A] 1m) will be informed if needed. Follow the data given and do the necessary steps to prevent
risks caused by noise or vibration in the operating conditions.

2.2.4.6 Radiation
The operators of the machine must fully follow the safety instructions related to the operation of this equipment.
2.2.4.7 Emissions
The instructions supplied with the machine give information on the control of leakages near the machine. If
necessary, perform the following measures to prevent dangerous emissions in the process:
- determine the amount of emissions and their potential effects (e.g. possibility of fire, applicable extinguishing
equipment)
- prevent the exposure of personnel to emissions
- keep the emissions under control and remove them in a controlled manner
- clean the area and machinery of emissions
- use applicable personal protective equipment and warnings
2.2.4.8 Slipping, stumbling and falling
When you install, service or repair the machine, follow the safety instructions applicable at the point of operation
and the instructions supplied with the machine and be sufficiently careful to prevent slipping, stumbling or falling.
2.2.5 Maintenance
2.2.5.1 Machinery maintenance
Follow the maintenance and repair instructions supplied with the machine. The instructions tell you when it is
necessary to stop and potentially drain the machine before maintenance. Wear applicable personal protective
equipment that is necessary for the maintenance task:
- hearing protectors
- eye protectors
- breathing protectors
- safety gloves, safety footwear, protective clothing
When you service or repair the machine, follow the principles of ergonomics (do not use too much muscular power,
use lifting equipment, lifting positions, lighting of the area, cleanliness etc.)
2.2.5.2 Access to operating position and servicing points
If the supply does not include location design for the machine, install the machine in a position that enables safe
maintenance and repairs of the machine.
When you design the operating environment make sure that there is sufficient maintenance space around the
machine.
2.2.5.3 Isolation from energy sources
The controls of the machine must include clearly identified devices that can be used to isolate the machine from all
energy sources. These devices must have locks if the re-connection of energy can be dangerous to persons. After
the energy supply is cut off, it must be possible to remove the energy stored in the process (e.g. release pressure)
without a health risk to persons.
2.2.5.4 Operator intervention
The controls of the machine must be designed so that the operator needs to intervene in the operation of the
machine as little as possible.
2.2.5.5 Cleaning of (internal) parts of machine
Refer to the instructions supplied with the machine and the safety instructions applicable at the point of operation to
do the potential cleaning of the machine safely.
2.2.6 Indications
2.2.6.1 Information and warning devices
Follow the specified requirements shown in the Machinery Directive and/or national legislation of the country where
the machine is used related to information and warning devices used in the machine.

2.2.6.2 Warning of residual risks
Keep the safety warnings related to the machine clean in all conditions and replace the warnings if necessary. All
operators of the machine must know the residual risks related to electricity or the controls. Refer to specified
requirements shown in the Machinery Directive and/or national legislation of the country where the machine is
used.
2.2.6.3 Marks and instructions
Follow the Machinery Directive and/or national legislation of the country where the machine is used in terms of the
marks and instructions for the machine. Make sure that the marks and instructions for other equipment related to
the safe operation of this machine comply with legislation.
Make sure that the point of operation has instructions for emergencies, such as:
- how to give alarm
- location of rescue and fire extinguishing equipment
- availability of first aid supplies and equipment
3. NECESSARY SAFETY PRECAUTION
Before you service the product, the operators and maintenance personnel must know all necessary safety
precautions.
WARNING
Always stop the drive unit before you repair the pump.
***
Make sure that the drive unit cannot be started during repair.
WARNING
Use personal protective equipment when you you service the product.
WARNING
Tools used in an explosive air mixture must comply with the requirements of the relevant
standard.
***
In a potentially explosive environment, the pump must be lifted and transferred so that no
sparking can occur.
WARNING
Remove any potentially dangerous materials from the pump before the maintenance
procedures.
WARNING
If it is possible that there is explosive gas or vapor inside the pump or piping, clean the
piping and pump with an efficient blower before you repair the pump.
***
If it is possible that there is explosive gas or vapor around the pump or in the servicing or
repair areas, ensure sufficient ventilation around the pump during the operation and
servicing of the pump.
WARNING
Do not expose the pump to heat when you disassemble the pump, because liquid trapped
in the pump can cause a risk of explosion.

WARNING
If there is a possibility of a dangerous return flow after the shutdown of the pump, install a
nonreturn device in the outlet piping.
WARNING
All safety devices (e.g. coupling guards) must be correctly installed before you start the
pump. Use guards with a non-sparking material for explosive areas.
WARNING
A leakage of a dangerous material can occur. Prepare the correct procedure for a safe
waste removal.
WARNING
The parts of the pump in contact with the liquid can be very hot. Do not touch them before
they are cool.
WARNING
The access of harmful bearing currents into the pump bearings must be prevented in
accordance with the instructions of the motor and frequency converter manufacturers.
CAUTION
Use the product only for the purpose for it is supplied. Refer to the correct operation
procedures described in these instructions.
CAUTION
Make sure that the product always has a shaft sealing system compatible with the pumped
liquid.
CAUTION
Verify the correct alignment of the coupling before you start the pump.
CAUTION
Do not start the pump before the system and the pump is filled up with the medium and
vented.
CAUTION
Do not operate the pump below the minimum recommended flow.
CAUTION
Make sure the suction valve is open during operation.

4. OPERATING CONDITIONS THAT HAVE AN EFFECT ON PRODUCT SAFETY
The operation conditions shown in table 1 always have a direct effect on product safety. Therefore, try to avoid the
following problems related to the servicing or operating conditions of the product.
Table 1, Typical non-permissible operating conditions

Cause: Consequence:
Discharge valve is closed. Pressure increases
Suction pressure has been estimated too low when pump was selected.
The pump is operated at too high a rotational speed.
Discharge valve is closed. High temperatures
Discharge valve is not open enough.
Incorrect estimate of properties of the pumped liquid when the pump was selected.
Failure of sealing water service High temperatures (Sealing unit)
- Sealing water pump not started
- Sealing water valve not opened
- Sealing water equipment incorrectly adjusted
- Quality of the sealing water does not correspond to the requirements.
Incorrect estimate of inlet pressure when the pump was selected.
Pump is not correctly filled with the pumped liquid.
- Suction valve not opened
- Suction tank not properly filled
- Suction piping resistance or air tightness incorrectly examined

5. TECHNICAL DATA
The individual pump technical data is found from the pump rating plate. The rating plate is stuck to the pump and to
the last page of this manual.
6. STRUCTURE
The pump with the integated motor is the set in which the impeller is mounted directly on the motor shaft. SD -
pump with the IEC motor is the set in which pump shaft is connected to the motor shaft with the coupling.
The pump impeller is installed directly onto the shaft of the electric motor (no separate couplings).
Fixed speed motor: Asynchronous motor (IE3 0,75-160kW)

400/230 V, 50 Hz 0,03–3 kW
690/400 V, 50 Hz (3)4–190 kW
(Exception: motor KP-112-2: L_-100S/4 3kW and AL_/AT-1129/4 3kW are equipped
690/400V motor)
Enclosure class: IP 54
0,03–4 kW 4-poles motor: 1500 r/min 50Hz and 1800 r/min 60Hz
IP 55
Insulation class: F
Duty type: S1 (continuous duty)
Ambient temperature: max. +45 °C
IEC-standard electric Asynchronous motor (IE2 or IE3) or Synchronous reluctance motor (IE4)
motor: 690/400 V, 50 Hz 4-90 kW
660/380 V, 60 Hz 4-90 kW
690/400 V, 60 Hz 4-90 kW
440 V, 60 Hz 4-105 kW
460 V, 60 Hz 4-110 kW
480 V, 60 Hz 4-110 kW
Note! In the data sheets, value of the nominal currents are indicated as approximate
values for
400 V, 50 Hz and 380-480 V, 60 Hz.
The exact values depend on the motor type, efficiency class and brand of motor.
That exact values are informed in the order confirmation and motors rating plate.
Enclosure class: IP55

Insulation class: F
Duty type: S1 (continuous duty)
Ambient temperature: max. +40 °C

7. SAFETY SYMBOLS
Sign of danger to persons Sign of voltage danger
ATTN Sign of danger to safe operation of the pump and/or protection of the pump itself
8. FIELDS AND LIMITS OF APPLICATION AND USE
Clean, thin, non-aggressive liquids

AE, AKN, AL, - circulating water for heating and cooling
AT, L, T - water-glycol mixtures, recommendation:
propylenglycol max. 40 %
Nominal pressure 10 bar

Max. temperature + 120°C (+ 100°C with plastic impeller)
AKNH, ALH, - for higher temperature liquids
LH
Max. temperature + 120°C normal
+ 150°C with special seal
+ 180°C with quench and special seal
Aggressive, thin, not bigger solid particles
containing liquids
ALM - in addition to above mentioned liquids various
acids, salts, oxidizing and chemically active
organic fluids
- sea water

Max. temperature + 120 - 180°C depending on seal
construction/materials used
Clean, thin, slightly aggressive liquids
AEP, ALP, - domestic water, oxygen rich waters
LP, AP - sea water

Max. temperature + 120°C (+ 100°C with plastic impeller)
containing liquids
ALS, LS - in addition to above mentioned liquids various
organic fluids

containing liquids
ALX, LX - in addition to above mentioned liquids various
organic fluids
- sea water


- heating and cooling circulating systems
KD - water-glycol mixtures, recommendation:
propylenglycol max. 40 %

Max. temperature +110°C
Aggressive, low viscosity, not big solid particles
containing liquids
K, KM - in addition to above mentioned liquids various
organic fluids

Max. temperature +110°C
ATTN Suitability of materials and seals for pumped liquid shall be always checked between purchaser
and supplier.
9. SAFETY PRECAUTIONS: HANDLING, TRANSPORT AND STORAGE OF THE PUMPS
You can find the total gross and net weights of the supply in the packing list attached to the product or packing.
WARNING
Observe all instructions regarding lifting and transport to prevent crashing of the box or
assembly.
Make especially sure that these items are stable:

- Pump
- Spare parts.
Always ascertain the center of gravity of these items before you lift or transfer the pump.
Use personal protective equipment such as helmet, safety shoes and gloves.
If the proper lifting equipment is not available, transfer heavy assemblies with for example skids on the ground
level.
Lifting accessories must have the identification of the manufacturer, material and the maximum working load.
Lifting ropes used directly for lifting or holding the pump or pump unit must not include splicing other than at their
ends. Textile ropes and slings must not include knots, connections or splicing other than at the ends of the sling.
This is not applicable to an endless sling.
Make sure that the lifting accessories can always sufficiently suspend the lifted assembly.
There must be a sufficient quantity of lifting ropes. Adjust them correctly to prevent damage to the product when
you lift it. A lifting chain must not touch the product during lifting (if it does, the painted and machined surfaces can
be damaged).
VARNING
Make sure that accepted and undamaged ropes and lifting accessories are available. The
lifting capacity of the lifting accessories and ropes must correspond to the weight of the
items you are lifting.
VARNING
In a potentially explosive environment, the pump must be lifted and transferred so that no
sparking can occur.

The heavier pumps are provided with lifting links.
Pumps shall be stored in a dry and cool place protected from dust.
In the case of longer storage time it is recommended to
rotate the pump manually f.ex. from the motor fan at
least once a month. When the pump serves as a stand-
by or is stopped for longer time for some reason, it is
necessary to start it for a while after two weeks
stoppage.
10. INSTALLATION AND START-UP
10.1 Installation
When installing the pump pay attention to the following:

- space enough for service and inspection of the pump
- possibility to use lifting mechanism if needed
- shut-off valves on the both sides of the pump
The position of the motor unit and the terminal box can be changed by removing the motor unit from the pump
housing and setting it to the desired position (not in AKN_ H, AL_ H L_ H external flushing).
10.1.1 Inline-pump with fixed speed motor

The smaller pumps (below 15 kW) can be mounted without the foot.
The heavier pumps should be fastened to a foundation of concrete which is

isolated from the floor f.ex. with 20 mm thick gum or cork plate(s). The weight of
the concrete foundation must be about 1.5 times the weight of the pump.

10.1.2 Inline SD-pump with IEC-standard motor
Inline SD-pumps are installed always on a base plate and vertical position.
Pumps should be fastened to a foundation of concrete which is isolated from the

floor f.ex. with 20 mm thick gum or cork plate(s). The weight of the concrete
foundation must be about 1.5 times the weight of the pump.
10.2 Electrical wiring
All electrical work shall be carried out by an electrician approved by the power supplier.
Check, that the voltage on the pump data plate corresponds to the mains voltage.
Standard connections:
Smaller motors (<4 kW) Bigger motors (≥(3)4 kW)
A starter must always be used and should be an ordinary motor protection breaker. Make sure that
ATTN the overload protection is set no higher than the rated current specified on the pump data plate.
Check the direction of rotation of the pump during start-up and always after re-connection. The flow direction is
indicated by an arrow on the pump housing or on fan cover
Never start or let the pump run dry. Before starting the pump fill and vent the system. Make sure that
ATTN
the pump rotates freely by rotating it manually f.ex. from the motor fan.
After starting make sure that there is no extra noise coming from the pump and that no leakages appear.
An inventer can be used for regulating the speed of rotation of the pump. An inverter must be
ATTN adjusted to prevent the overload of the motor. The current switch-off is to be adjusted according to
rated current. Note. The use of over 50 Hz frequency may cause the overload of the motor. The
motor suitability for frequency drive use must be ensured if the supply voltage is more than 500V.

11. MAINTENANCE AND REPAIR
The pump doesn’t need any regular servicing.
As a shaft seal is used an adjustment free mechanical seal. It is a wearing part which has to be replaced if it starts
to leak. Note that few drops leakage per hour can be quite normal especially when coolants (f.ex. glycol) are
pumped.
11.1 Single mechanical shaft seal; type constructions
1 Rotating ring
2 Stationary ring
3 Body/bellows
4 Spring
5 O-ring
6 Backing plate
(not always)
The motor is equipped with ball bearings which are lubricated for life and therefore do not need any service. In the
case of any motor malfunction it is recommended to replace the whole exchange unit.
11.2 Rating plate
When ordering spare parts, please specify the pump type, serial number, duty point, the size of impeller, the motor
type and power.
11.2.1 Pump with integrated motor
Pump type Motor code

Serial number Impeller diameter and material
Duty point
Motor type
11.2.2. Pump with IEC-standard motor
Pump type Manufacturing year and month

Serial number Impeller diameter and material
Duty point Nominal power of motor
11.2.3. Example of rating plate for IEC-standard motor
Motor type
Rating

12. PARTS FOR PUMP
12.1 Pump with integrated motor (flanged connections)
POS.NO. DESCRIPTION
1 ELECTRICAL MOTOR 2 PUMP HOUSING

3 IMPELLER 5 SEALING FLANGE
8 BASE PLATE (not always) 16 COVER (T- and AT-serie)
24 SCREW OR NUT 25 WASHER
26 KEY 40 SHAFT SEAL
50 O-RING 55 O-RING (T- and AT-serie)
60 SCREW OR NUT 65 SCREW (T- and AT-serie)
67 SCREW 80 PIPE UNION (Internal flushing)
81 PIPE UNION (Internal flushing) 86 COOLING PIPE (Internal flushing)
93 FLAP (T- and AT-serie) 94 CYLINDICAL PIN (T- and AT-serie)

12.2 Pump with integrated motor (thread connections)
POS.NO. DESCRIPTION
1 ELECTRICAL MOTOR
2 PUMP HOUSING
3 IMPELLER
5 SEALING FLANGE
24 NUT
25 WASHER (not always)
26 KEY
40 SHAFT SEAL
43 V-RING
50 O-RING
60 SCREW
80 PIPE UNION 2 piece
12.3 End-suction (KD, K, KM)
POS.NO. DESCRIPTION
1 ELECTRICAL MOTOR
2 PUMP HOUSING
3 IMPELLER
5 SEALING FLANGE
24 SCREW
25 WASHER
26 KEY
40 SHAFT SEAL
50 O-RING
60 SCREW OR NUT

12.4 SD-pump with IEC-standard motor (flanged connections)
POS.NO DESCRIPTION
1 ELECTRICAL MOTOR
2 PUMP HOUSING
3 IMPELLER
5 SEALING FLANGE
6 MOTOR BRACKET (ADAPTER)
8 BASE PLATE
14 COUPLING
21 FLANGE-SHAFT
22 SCREW
24 SCREW
25 WASHER
26 KEY
40 MECHANICAL SHAFT SEAL
50 O-RING OR GASKET
60 SCREW / NUT
62 SCREW
67 SCREW
70 SCREW / NUT
73 SCREW
80 PIPE UNION (Internal flushing)
81 PIPE UNION (Internal flushing)
86 PIPE (Internal flushing)
89 WASHER
92 COUPLING PROTECTION
.

13. REPLACING EXCHANGE UNIT
13.1. Less than 1,5kW

Note! Only an authorized person may carry out the replacement.
Starting situation. The pump is running normally.
1) Stop the pump, open any 2) Detach the motor cable.

possible safety switch and Open the screws/nuts of the
remove fuses. Ensure that operating unit.
no one is able to switch the
current on, even by
accident, during the
replacement. Close the
valves.
3) Lift the operation unit 4) Replace the gasket/O-ring

from the pump housing. of the housing.
Watch out for hot water!
5) Install a new exchange 6) Connect the motor cable

unit. Tighten the and open the valves. Start the
screws/nuts of the unit pump and check the direction
of rotation. Vent the system.
evenly. Monitor the operation of the
pump.
13.2 Over 1,5kW

Note! Only an authorized person may carry out the replacement.
Starting situation: The pump is running normally.
1) Stop the pump, open a 2) Close the valves and detach

possible safety switch the connecting cable of the
and remove fuses. motor. Next, detach the flush pipe
Ensure that no one is (in AKN_ H, AL_ H and L_ H -
able to switch the current pumps). Open the screws/nuts of
on, even by accident, the operation unit.
during the replacement.
Close the valves.
3) Lift the exchange unit 4) Replace the gasket/O-ring of

by means of a hoist. the housing.
Watch out for hot water!
5) Install a new 6) Connect the motor cable and

exchange unit. Tighten open the valves. Start the pump
the screws/nuts of the and check the direction of
unit evenly. rotation. Vent the system. Monitor
the operation of the pump.

14. REPLACING IMPELLER
1) Detach the exchange unit 2) Install the exchange unit in a
as usual (see 13. Replacing vertical position.
exchange unit).
3) Open the screw/nut of the 4) Use screwdrivers to detach

impeller. the impeller.
5) Use an extractor if 6) The exchange unit is without

necessary. Pull out the an impeller. Replace the shaft
impeller at the impeller seal when necessary (see 16.
wings. Replacing shaft seal).
7) Install a new impeller. If 8) Attach the exchange unit as

required, you can lightly tap usual.
the impeller with a rubber
mallet until flush with the
ridge. Tighten the screw/nut
of the impeller.
In the twin pump installation it is possible to substitute the

damaged unit by a blind cap (to be ordered separately).
The other unit can be driven then normally.

15. REPLACING IEC-STANDARD MOTOR FOR SD-PUMP
Starting situation: The pump is

running normally.
1) Stop the pump, open a

possible safety switch and
remove fuses. Ensure that no one 2) Lift the
is able to switch the current on, exchange unit
even by accident, during the by means of a
replacement. Close the valves hoist. Watch out
and detach the connecting cable for hot water!
of the motor. Next, detach the
flush pipe (in AKN_ H, AL_ H and
L_ H -pumps). Open the
screws/nuts of the operation unit.
3) Open the
screw/nut of the
impeller. Use an 4) Detach
extractor if the shaft
necessary. seal
6) Detach
5) Detach motor
sealing flange. bracket
(adapter)
from electric
motor.
7) Detach flange-
shaft. 8) Detach
coupling
from the
motor shaft.
9) Install 10) Align

coupling, flange- flange-shaft
shaft and motor using a
bracket to new measuring
motor. Use gauge.
threadlocker The max.
Loctite 2701. allowed run-
out is 0.08.
11) Align the 12) Assamble the exchange unit by the

flange reverse order of steps 1 to 5.
perpendicularity
run-out to motor
shaft using a
measuring
gauge. The max.
allowed run-out is
0.15.

16. REPLACING SHAFT SEAL
16.1 Detaching seal

Stop the pump and close the shut-off valves. Detach the exchange unit from the pump housing. (see 13. Replacing
exchange unit). Detach the impeller of the pump (see 14. Replacing impeller).
1) Starting situation. The 2) Detach the shaft seal using

motor unit with the impeller two screwdrivers. Do not
detached. damage the sealing surface
of the shaft.
3) Also detach the sealing 4) The motor unit

flange from the motor front disassembled, with
plate using two screwdrivers. installation tools.
If needed, replace the sealing
flange with a new one.
16.2 Installing mechanical seal
16.2.1 Lubricating and installing O-ring

NOTE! Touch the seal parts with clean hands only,
and as little as possible and with extreme care.
Check the housing and O-ring groove for the

stationary ring in the sealing flange are clean. Check
the O-ring and lubricate it with soap water, not with
oil. Then install the O-ring in the groove of the sealing
flange (in the stationary ring for BO- and BP-marked
seals).

16.2.2 Pressing stationary ring into the sealing
flange
Check that the stationary ring is undamaged, clean,
smooth and not scratched. If the stationary ring is
packed in protective foil, detach it with a knife,
carefully minding the rotating surface. Then, remove
the grease with a dry and clean cloth. Press the
stationary ring into the sealing flange with the
smoother surface facing you (the pump). Ensure that
the O-ring does not push the ring out. If this happens,
use more lubrication. Finally, clean the rotating
surface of the stationary ring with a clean and lint-free
cloth or towel which is dampened with a suitable
organic solvent, e.g. methyl alcohol or spirit.
Alternatively, the stationary ring can be installed with
a clean lint-free cloth without fingers touching the
rotating surface. Finally, the rotating surface should
be blown clean with compressed air.
16.2.3 Installing sealing flange onto D-end motor

flange
Install the sealing flange onto the motor. Place the
assembly sleeve of the installation tool so that it
forms a shaft extension. In large pumps, first install
the sealing flange onto the motor and then the
stationary ring (BO- and BP-marked seals).
16.2.4 Assembly sleeve as shaft extension
16.2.5 Soaping assembly sleeve

Check that the seal body, bellows and rotating ring
are clean and undamaged. If the rotating surface of
the rotating ring is dirty, clean it with a clean and lint-
free cloth which is dampened with a suitable organic
solvent, e.g. methyl alcohol or spirit. Lubricate the
shaft and the seal elastomer bellows suitably with
soapy water, not with oil.

16.2.6 Pushing bellows onto shaft
Detach the spring (if separate) and, using even
pressure, push the bellows onto the shaft using the
installation mandrel until the rotating surfaces meet.
Do not press too hard. If the spring is attached to the
frame, install the whole seal onto the shaft from its
bellows part (end of seal) by pushing with a suitable
sleeve. If the rotating ring of the seal does not stay
fast in the seal, install it first and ensure that when
installing the seal frame, the frame and the rotating
ring are in place correctly.
Note! Do not touch the rotating surface of the rotating

ring.
16.2.7 Installing spring, back plate and impeller

Rotate the shaft sligtly and carefully and ensure that
the seal fits well. Then, install spring, back plate
(if separate) and impeller.
NOTE!: Never start or let the pump run dry.

DECLARATION OF CONFORMITY
We, Kolmeks Oy, Taimistotie 2, FI-14200 Turenki FINLAND
declare under our sole responsibility for inline-pumps, to which this
declaration relates, are in conformity with the:
- Machinery Directive 2006/42/EY
- EMC- directive 2014/30/EU
- Low voltage directive 2014/35/EU
- Standard EN 809:1998+A1:2009 Pumps and pump units for
liquids.
Common safety requirements.
- Ecodesing directive 2009/125/EY Regulations: 547/2012 for water pumps
640/2009 for electric motors
- RoHS- directive
2011/65/EU
Turenki 12.03.2019
Jyrki Vesaluoma
Chairman of the board Kilpitarra
Responsible of technical
file:
Kolmeks Oy
Taimistotie 2
FI-14200 TURENKI
Finland
MINIMUM EFFICIENCY INDEX MEI
The efficiency of a pump with a trimmed impeller is usually lower than that of a pump with full impeller diameter.
The trimming of the impeller will adapt the pump to a fixed duty point, leading to reduced energy consumption.
The minimum efficiency index (MEI) is based on full impeller diameter.
The operation of this water pump with variable duty points may be more efficient and economic when controlled,
for example, by the use of a variable speed drive that matches the pump duty to the system.
For pumps supplied after 1.1.2015 regulation 547/2012 is to be applied, Minimum Efficiency Index MEI > 0,4,
benchmark for the most efficient water pumps is MEI > 0,7. Information on benchmark efficiency is available at:
www.europump.org/efficiencycharts
Kolmeks Oy Taimistotie 2, PL 27, FI-14201 TURENKI, Finland P. +358 20 7521 31

sales.finland@kolmeks.com, www.kolmeks.fi

Appendix D - Particle Filter and Back Flush Pump

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Appendix D - Particle Filter and Back Flush Pump

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Particle filter and backflush pump

Date Version Language Order no. Item no.

Operating instructions aquaBoll 6.18.3 3 / 108

4 / 108 Operating instructions aquaBoll 6.18.3

Operating instructions aquaBoll 6.18.3 5 / 108

1.2 Warranty and liability

• improper use of the filter,

Operating instructions aquaBoll 6.18.3 7 / 108

The copyright of the document is held by

8 / 108 Operating instructions aquaBoll 6.18.3

2.2 Warning signs and symbols

2.3 Target group

Operating instructions aquaBoll 6.18.3 9 / 108

10 / 108 Operating instructions aquaBoll 6.18.3

Operating instructions aquaBoll 6.18.3 11 / 108

• Follow the respective valid national and international accident prevention

2.6.2 Maintenance and servicing

2.7.1 Filtered media

2.7.2 Cleaning agent

2.8 Safety instructions for operating personnel

12 / 108 Operating instructions aquaBoll 6.18.3

Operating instructions aquaBoll 6.18.3 13 / 108

3.3 Packaging material

Operating instructions aquaBoll 6.18.3 15 / 108

Operating instructions aquaBoll 6.18.3 17 / 108

Fig. 5-1 Suspension points

5.1 Type plate

Operating instructions aquaBoll 6.18.3 19 / 108

5.2 Tightening torques and

20 / 108 Operating instructions aquaBoll 6.18.3

Applies to DN 200 - DN 500

Fig. 5-2 Overview of assembly groups

1 Gear motor 6 Measuring connection

Operating instructions aquaBoll 6.18.3 21 / 108

Fig. 5-3 Overview of assembly groups

22 / 108 Operating instructions aquaBoll 6.18.3

Fig. 5-4 Overview of assembly groups (cross sectional view)

1 Drive shaft 8 Flushing line socket

Operating instructions aquaBoll 6.18.3 23 / 108

Operating instructions aquaBoll 6.18.3 25 / 108

6.2.1 Floor fastening

1 Lower section of housing

 Make sure the foundation has sufficient load-bearing strength.

26 / 108 Operating instructions aquaBoll 6.18.3

Fig. 6-2 Installation diagram

1 Grating/suction 8 Bypass line

Operating instructions aquaBoll 6.18.3 27 / 108

6.2.4 Pipe connections for filter inlet and filter outlet

6.2.5 Flushing line pipe connection

 Establish the connection between the flushing line and piping.

6.2.6 Compressed air supply connection (on pneumatically actuated flushing

 Connect the plant's compressed air supply to the solenoid valve.

28 / 108 Operating instructions aquaBoll 6.18.3

Fig. 6-3 Gear motor installation

1 Hand winch 4 Cover

 Clean cover and gear motor flange.

Operating instructions aquaBoll 6.18.3 29 / 108

Fig. 6-4 Direction of rotation of the motor

 Remove the hand winch from the gear motor.

30 / 108 Operating instructions aquaBoll 6.18.3

Differential pressure monitoring system, electrical

Operating instructions aquaBoll 6.18.3 31 / 108